Spherical Roller Surface Treatment for Skid-Free Compressive Stressing
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Solution Overview
Problem
Existing mechanical surface treatment systems for components, such as aerospace components, lack efficiency in imparting compressive stresses below the surface and often result in skidding or non-rolling motions during treatment.
Innovation Solution
A system comprising a tool with a spherical roller, a roller support, a spherical bearing element, a bushing, and a spring element, which allows for a static pressure load application and rolling motion along the component surface, minimizing skidding through a biasing mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mechanical surface treatment systems are used, then compressive stresses are imparted to the component surface, but skidding or non-rolling motions occur during treatment reducing efficiency
Solution Approach 1:
The patent employs a spherical roller instead of conventional cylindrical or flat rollers. The spherical geometry enables pure rolling motion without skidding because the contact point continuously changes, eliminating the tendency for lateral slipping that occurs with conventional roller shapes. This spherical configuration maintains consistent rolling contact with the component surface, ensuring treatment efficiency and reliability simultaneously.
Solution Approach 2:
The patent changes the geometric parameter of the roller from cylindrical to spherical, fundamentally altering the contact mechanics. This parameter change transforms the motion characteristics from potential skidding to pure rolling, resolving the contradiction between treatment efficiency and motion stability by modifying the fundamental geometry of the treating tool.
2Strength
If a static pressure load is applied through the spherical roller, then compressive stresses are effectively imparted below the surface, but the system complexity increases with biasing devices
Solution Approach 1:
The patent employs a spring element as a biasing device that applies continuous static pressure load through the spherical roller onto the component surface. The spring provides the necessary counteracting force to maintain consistent contact pressure, enabling effective compressive stress imparting. While this adds a biasing mechanism, the spring is a simple, reliable component that minimizes overall system complexity while achieving the desired strength improvement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively imparts compressive stresses beneath the component surface, enhancing damage tolerance and fatigue life by up to ten times, while maintaining smooth rolling without skidding.
Implementation Method 1
The spring element is disposed in the internal cavity and biased longitudinally against the bearing. The spring element is configured to bias the spherical roller against the endwall through the spherical bearing element and the bushing.
Implementation Method 2
The manipulator is configured to move the tool along the surface of the component such that the spherical roller rolls along the surface of the component. The manipulator is configured to apply a static pressure load against the surface of the component through the spherical roller.
Data Source
AI summary
A system for mechanical surface treating a component includes a tool and a manipulator. The tool includes a roller support, a spherical roller and a biasing device. The roller support includes an endwall, a port and an internal cavity. The roller support extends longitudinally along a longitudinal axis to the endwall. The port extends from the internal cavity through the endwall. The spherical roller is nested in the port with an exposed portion of the spherical roller projecting out of the roller support from the port. The exposed portion of the spherical roller is configured to contact a surface of the component. The biasing device is disposed in the internal cavity and biases the spherical roller against the endwall. The manipulator may move the tool along the surface of the component. The manipulator may apply a static pressure load against the surface of the component through the spherical roller.